Post-seal inspection system and method

ABSTRACT

A system for inspection components that are sealed within tape is provided. The system includes a light source that can illuminate the components through a tape layer. A polarizer is used to polarize light from the light source, the components, and the tape layer, so as to reduce glare and reflected light. An image system receives light from the polarizer and stores image data for each component.

FIELD OF THE INVENTION

[0001] The present invention relates to inspection systems, such asthose used to inspect surface mount type semiconductor devices, and moreparticularly to systems and methods for inspection of components throughsealing or cover tape after the components have been sealed with thetape.

BACKGROUND OF THE INVENTION

[0002] Unintended deformation of semiconductor devices may be awell-known problem in the semiconductor industry. This problem has beenaddressed by inspecting semiconductor devices and components both before(pre-seal) and after (post-seal) the devices or components are packagedfor shipping. Existing methods for performing post seal inspectionrequire the use of an operator to perform 100 percent inspection,because of variability in the sealing tape used for immobilizingsemiconductor devices and components.

[0003] The current process used by most manufacturers is to do anautomated vision inspection at pre-seal and a post seal gross manualinspection. The post seal gross manual inspection involves examining thedevices with the human eye through a magnifying glass. Although doing amanual post seal inspection is better than doing no post seal inspectionat all, the manual post seal inspection is very time consuming and notvery cost effective and therefore not very efficient. In addition, asmore and more semiconductor processes become automated, a manual postseal inspection becomes less desirable.

[0004] No automated method has been developed that can examine thesemiconductor devices for defects after the devices have packaged forshipping. The problem has been the ability to generate a clear anddetailed image of the semiconductor device when such device is disposedbeneath a layer of sealing or cover tape. The sealing or cover tapelayer causes extreme light scattering and light reflection, which canseverely distort the image of the device beneath the tape. Because ofthis image distortion caused by the sealing or cover tape layer, thepractice in the field has been to merely do a manual post sealinspection of devices packaged under sealing or cover tape.

[0005] Although it is desirable to automate all inspection processes forsemiconductor devices and components, many physical obstacles haveprevented an automated post seal inspection system for devices andcomponents disposed beneath the sealing or cover tape. The glossy covertape causes light reflection and light dispersion, which creates noisewhen a camera is trying to produce an image of the device. The covertape is not very translucent so the clarity of the device disposedbeneath the tape is impaired. Also, the cover or sealing tape hasanti-static coating as well as filler particles that worsen visibilitythrough the cover or sealing tape. Finally, the inside and outsidesurfaces of the cover or sealing tape are not perfectly parallel whichcreates a prism and cause the device disposed beneath to appeardistorted.

SUMMARY OF THE INVENTION

[0006] This invention provides a system and method relating to anautomated vision inspection system in which there may be a systemconfigured to store image data and perform analysis on such image dataof a component disposed beneath a tape layer. The image data is capturedby shining a light source on the component and then filtering both theincident and reflected light to reduce light reflection and scatteringeffects in the image data. In addition, the cover or sealing tape layeris stretched to remove surface unevenness in the tape layer. Finally,the components are put as close as possible to the cover or sealing tapelayer to increase visibility of the component disposed beneath the tape.

[0007] In accordance with another aspect of the present invention, theautomated post seal vision inspection system can be coupled to a packingmedia transfer system or taping/de-taping machine to facilitate in theremoval found to be unacceptable during the automated post seal visioninspection.

[0008] The technical advance represented by the invention, as well asthe objects thereof, will become apparent from the following descriptionof a preferred embodiment of the invention when considered inconjunction with the accompanying drawings, and the novel features setforth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 illustrates an overall view of a post-seal inspectionsystem in accordance with an exemplary embodiment of the presentinvention.

[0010]FIG. 2 is a detailed and expanded diagram of a tape stretching andinversion mechanism in accordance with an exemplary embodiment of thepresent invention.

[0011]FIG. 3 is a detailed and expanded diagram of a light source andpolarizer system in accordance with an exemplary embodiment of thepresent invention.

[0012]FIG. 4A is a plan view of a light source in accordance with anexemplary embodiment of the present invention.

[0013]FIG. 4B is a section view of FIG. 4A showing further details ofthe light source in accordance with an exemplary embodiment of thepresent invention.

[0014]FIG. 5 is a diagram showing a post-seal inspection system coupledto a packing media transfer system in accordance with an exemplaryembodiment of the present invention.

[0015]FIG. 6 is a flowchart of a method of operation for a post-sealinspection system in accordance with an exemplary embodiment of thepresent invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0016] In the description which follows, like parts are markedthroughout the specification and drawing with the same referencenumerals, respectively. The drawing figures may not be to scale andcertain components may be shown in generalized or schematic form andidentified by commercial designations in the interest of clarity andconciseness.

[0017]FIG. 1 is a diagram of a post seal inspection system 100 inaccordance with an exemplary embodiment of the present invention. Postseal inspection system 100 allows components to be inspected after theyhave been sealed in packing tape, thus allowing the defective componentsto be readily detected and corrective measures to be taken beforecomponents are shipped to the ultimate user.

[0018] Post seal inspection system 100 includes tape 102 and stretchingand inversion mechanism 106. Tape 102 may be an embossed polymer tapewith a bottom embossed layer and a top sealing layer, wherein the topsealing layer is sealed with adhesive, vacuum, heat or other suitablemethods. Other suitable tape sealing mechanisms may also be used.Stretching and inversion mechanism 106 is used to invert tape 102 suchthat the embossed pocket portion of tape 102 is on top and the sealingportion of tape 102 is underneath. This configuration allows gravity toforce the component to lay flush against the sealing tape, therebyenabling automatic optical inspection of the component through thesealing layer of tape 102.

[0019] Post seal inspection system 100 includes feeder reel 104 andtake-up reel 118. Feeder reel 114 may contain components that have beensealed in tape 102. Tape 102 is fed into stretching and inversionmechanism 106 and is then fed into take-up reel 118. Feeder reel 114 andtake-up reel 118 operate in a coordinated manner such that the speed ofthe tape 102 is controllable through the stretching and inversionmechanism 106.

[0020] In addition to inverting tape 102, the stretching and inversionmechanism 106 also stretches tape 102 by forcing tape 102 through asemi-circular path. The stretching effect of the semi-circular path ofthe stretching and inversion mechanism 106 helps to insure that thesealing portion of tape 102 will present a uniform surface forinspection of the components while the inversion effect insures that thecomponents sealed in tape 102 will be placed against the sealing portionof tape 102. Although a single element is used in this exemplaryembodiment to invert and stretch the tape, a system for inverting thetape may be used that is separate from the system for stretching thetape, such as a series of rollers and gears.

[0021] Post seal inspection system 100 includes camera 116, which iscoupled through optical wave guide 114 to light source 110 andpolarizers 108 and 112. Light source 110 generates light that is focusedon the components and tape 102. This light is transmitted throughpolarizing filters 108 and 112 and back through the optical wave guide114 to camera 116. Light source 110 and polarizers 108 and 112 may belocated at the location shown in FIG. 1, which is approximately at a 45degree angle from vertical, or may alternatively be located at othersuitable locations.

[0022] Light source 110 may be a light emitting diode array, a filamentlight array, or other suitable lighting arrays. Light source 110 may bea controlled light source, which generates a predetermined light patternon tape 102 at a predetermined spot on the stretching and inversionmechanism 106.

[0023] The light generated by light source 110 is transmitted firstthrough polarizer 108. Polarizer 108 may be configured to be adjustableby an operator, and may be a polarizing element that is configured topolarize light that is transmitted from light source 110 to tape 102.The light reflects off tape 102 and the components contained therein,and is transmitted back through polarizer 108 and then through polarizer112. Polarizer 112 may be a polarizing element that may be configured tobe adjustable by an operator so as to compensate for reflectionsgenerated by the surface of the sealing layer of tape 102.

[0024] In one exemplary embodiment, light that is transmitted directlythrough the sealing layer of tape 102 will be oriented in the same phaseas the light emitted by the light source, but light that is scattered bytape 102 or otherwise reflected off a discontinuity in tape 102 willhave a different phase. Polarizer 108 thus provides planepolarized lightto illuminate the components sealed in tape 102. Polarizers 108 and 112may be configured to be controllably adjusted so as to transmit thegreatest amount of light that has not been reflected off discontinuitiesor otherwise scattered by tape 102. Alternatively, light source 110 maybe configured to generate phase-oriented light, such as laser light, andpolarizers 108 and 112 may be set to provide an optimum level oftransmission of non-reflected light.

[0025] Optical wave guide 114 may be a suitable optical channel, and maybe a nondistorting optical guide such as high precision mirrors. Camera116 is configured to receive the image generated by light source 110through optical wave guide 114. Camera 116 may be a charge coupleddevice, an optical sensor array, or other suitable digital camera thatis operable to capture and store image data, such as a 512×1024 pixelimage. Camera 116 may process black and white image data, color imagedata, or other suitable image data.

[0026] Camera 116 is coupled to inspection system 120. Inspection system120 may be implemented in hardware, software or a suitable combinationof hardware and software, and may be an inspection platform withprogrammable software systems. In one exemplary embodiment, inspectionsystem 120 may be a WAV1000 System manufactured by SemiconductorTechnologies and Instruments of Richardson, Tex. Inspection system 120receives digital image data from camera 116 and performs predeterminedanalysis functions on the image data. In another exemplary embodiment,inspection system 120 may compare referenced image pixel data to testimage pixel data to determine whether the pixel data is withinpredetermined acceptable ranges. Inspection system 120 may also receiveuser entered template data to facilitate the setup and testing ofcomponents stored within tape 102.

[0027] Inspection system 120 is coupled to marking system 122. Markingsystem 122 is operable to mark components that are determined to benon-standard by inspection system 120. For example, marking system mayrecord an index number on the tape 102 that corresponds with thelocation of the suspect device. Marking system 122 may also physicallymark the tape or use other suitable methods to indicate or record thelocation of a suspect device.

[0028] In operation, tape 102 is inverted and stretched by thestretching and inversion mechanism 106 to facilitate optical testingafter sealing. An image of each component sealed within tape 102 isgenerated by camera 116, which receives calibrated image data from lightsource 110, polarizer 108, and polarizer 112. Inspection system 120 isconfigured to process the image data to determine whether the componentsealed in tape 102 meets predetermined criteria for acceptability.

[0029]FIG. 2 is a diagram of a tape stretching and inversion mechanism106 in accordance with an exemplary embodiment of the present invention.Tape stretching and inversion mechanism 106 may be used to ensure thatthe sealed components contained within sealing tape are properlyoriented prior to performing the post-seal inspection.

[0030] Tape stretching and inversion mechanism 106 includessemi-circular component 202 and 204, which are each made of metallicmaterials, composite materials, or other suitable materials.Semi-circular component 202 includes track 205 and semi-circularcomponent 204 includes track 206. Tracks 205 and 206 are used to controlthe path taken by tape 208 as it passes through the stretching andinversion mechanism 106. Tape 208 leaves a suitable feeder mechanism,such as feeder reel 104 of FIG. 1, and enters the stretching andinversion mechanism 106 in the direction indicated by arrow “A.” Aftertape 208 enters the stretching and inversion mechanism 106, tape 208follows the semi-circular tracks 205 and 206 and moves past the areaindicated by arrow “B,” and then moves out of the stretching andinversion mechanism 106 at the location indicated by arrow “C.” Tape 208is then collected on a suitable collection mechanism, such as take-upreel 118.

[0031] Tape 208 is disposed around components 210, which are inspectedwhile tape 208 is being inverted and stretched by tape stretching andinversion mechanism 106. Tape 208 with components 210 enters thestretching and inversion mechanism 106, and the components 210 fall ontothe sealing layer of tape 208 by the force of gravity at or before thelocation shown by arrow “B.” In addition, the sealing layer of tape 208is stretched along the semicircular tracks 205 and 206 of tapestretching and inversion mechanism 106. Thus, the components disposedwithin tape 208 are placed in a position that is relatively uniform atthe location shown by arrow “B,” namely, flush against the sealing layerof tape and with the sealing layer of tape stretched taught. Thisconfiguration allows a suitable system to obtain digital images of thecomponents disposed within tape 208, and to also obtain a digital imageof the seal of tape 208 in the area near the component.

[0032] After the tape 208 has been stretched and inverted by stretchingand inversion mechanism 106, it may be collected by a suitablecollection mechanism. Also or alternatively, tape 208 may be processedby a detaping system, if the post-seal inspection of the tape 208indicates that a damaged component or improper seal has been identified.An operator may also or alternatively be notified when a damagedcomponent or improper seal has been identified, so that the operator mayperform additional analyses of the sealed component to determine whethera need exists to remove or reseal the component.

[0033]FIG. 3 is a diagram of a light source and polarizer system 300 inaccordance with an exemplary embodiment of the present invention. Lightsource and polarizer system 300 is used to generate an image of acomponent that is disposed beneath a tape layer that may beelectronically recorded and analyzed to detect seal and componentirregularities.

[0034] Light source 110 may be an array of light-emitting diodes orother suitable light sources that generate light having a controllablepattern and intensity. Light source 110 emits light in the directionshown by arrow “A,” such that the light passes through polarizer 108.Polarizer 108 is a polarizing element that causes the light emitted bylight source 110 to become polarized. In one exemplary embodiment,polarizer 108 is a transparent material that transmits light photons inwhich the electric vector of the light electromagnetic radiation isoriented in a predetermined plane, and blocks light photons in which theelectric vector is oriented in a plane that is orthogonal to thetransmission plane. In this manner, all light generated by light source110 that passes through polarizer 108 will be plane-polarized.

[0035] The plane-polarized light follows the path shown by arrow “C” andpartially passes through, is partially scattered by, and is partiallyreflected off of sealing tape layer 306. The plane polarized lightilluminates component 308, which rests in embossed carrier tape 310. Theplane-polarized light is then emitted from component 308, and passesback through sealing tape layer 306 in the direction of arrow “E.” Thelight travelling in the direction of arrow “E” therefore includes planepolarized light that has been emitted from component 308,plane-polarized light that has been reflected off of sealing tape layer306, plane polarized light that has been scattered by sealing tape layer306, and other incident light that been reflected off of component 308and sealing tape layer 306.

[0036] The light travelling in the direction of arrow “E” then passesthrough aperture 320 of polarizer 108. The light continues in thedirection shown by arrow “G” through aperture 318 of light source 110.The light then travels in the direction of arrow “I” through polarizer112.

[0037] Polarizer 112 is a polarizing element. In one exemplaryembodiment, polarizer 112 is a transparent material that transmits lightphotons in which the electric vector of the light electromagneticradiation is oriented in a predetermined plane, and blocks light photonsin which the electric vector is oriented in a plane that is orthogonalto the transmission plane. Polarizer 112 may be adjusted by an operatorto function an analyzer, so as to further eliminate light scatteringwhich may have been caused by shining light from light source 110 ontocomponent 308 through sealing tape layer 306. Light travelling in thedirection of arrow “K” exits polarizer 112, and is intercepted by camera116.

[0038] Camera 116 is an electro-optical device that may be used tocreate a digitally-encoded image. Camera 116 may include a predeterminednumber of picture elements, or pixels, that are operable to receivelight or other electromagnetic radiation having a predeterminedfrequency range. Each picture element may generate a digital value thatis representative of the intensity of light being received by thatpicture element at a point in time. Camera 116 is operable to store suchpicture element data in a coordinated manner, so that an image may begenerated using the picture element data.

[0039] In operation, light source and polarizer system 300 is used togenerate and store digital image data of a component that is disposedbeneath a transparent tape layer. The component is initially oriented ina manner that causes the component to be placed flush against a sealinglayer of tape. The sealing layer is also stretched taught, to providefurther assurance that the component is in a known location and toreduce the amount of distortion, scattering, and glare that may becreated by the sealing tape layer. A light source is then used toilluminate the component, and polarizing elements are used to eliminateglare and other reflected light so as to allow a camera to generate adigital image of the component that has not been distorted, obscured, orotherwise rendered unusable. The digital image may then be analyzed todetermine whether the component has been damaged or inadvertentlypackaged, based upon predetermined data.

[0040]FIG. 4A is a plan view of light source 110 in accordance with anexemplary embodiment of the present invention. FIG. 4B is a section viewshowing further details of light source 110, polarizer 108, andpolarizer 112, as they may be contained within an exemplary housingsupport 410.

[0041] Light source 110 is composed of a suitable support 402, which maybe configured in the form of a generally circular ring. Support 402includes an aperture 408. Aperture 408 allows for the viewing of thecomponent and the capturing of the image of the component by the visionengine, and further allows reflected light to pass back through lightsource 110 and other components without altering the image data orcreating additional light or glare.

[0042] Light source 110 may one or more circular arrays 404 of lightemitting elements 406. Alternatively, other shapes or arrangements maybe used, such as squares, ellipsoids, or other suitable arrangements.The light emitting elements 406 of light source 110 may be lightemitting diodes, incandescent light element, fluorescent light elements,or other suitable light elements.

[0043]FIG. 4B shows a housing support 410 that holds light source 110,polarizer 108, and polarizer 112. The light emitting elements 406 oflight source 110 are held in proximity of polarizer 108. Aperture 320 ofpolarizer 108 allows polarized light that has been emitted by components308 to be passed through without additional polarization. The light alsopasses through aperture 318 of light source 110 and aperture 408 ofhousing support 410, and is filtered by polarizer 112. Polarizer 112 isadjustable within housing support 410, such that polarizer 112 may beadjusted to compensate for the amount of scattered light that isreceived from tape 102.

[0044] In operation, light emitted from light source 110 is passedthrough polarizer 108 and illuminates a component 308 that is disposedbeneath a sealing tape layer 306. The component 308 emits polarizedlight, and the sealing tape layer 306 emits reflected and scatteredpolarized light. A second polarizer 112 may be adjusted within a housingsupport 410 to block a suitable level of the reflected and scatteredpolarized light, while allowing a sufficient amount of polarized lightto pass to form an image in a camera or other suitable device. In thismanner, components that have been sealed within a layer of tape may beinspected for damage, anomalies, non-conformities, or other unacceptableconditions.

[0045]FIG. 5 is a diagram of a packing system 500 that includes a postseal inspection system 100, in accordance with an exemplary embodimentof the present invention. Packing system 500 allows components to beremoved from packing tape in an automated process if such components aredetermined to be defective by post seal inspection system 100.

[0046] Packing system 500 includes tape 102, which leaves feeder reel104 and receives components 504 at a tape/detape system 580. Tape 102comprises two components prior to receiving components 504, namely, anembossed portion and a sealing layer. As tape 102 is fed into packingsystem 500, it is held by supports 508 while a pick and place head 512of a robot arm 514 is used to pick up components 504a from a packingtube 516. Device handling controller 506 is used to control theadvancing of tape 102, and also controls the operation of pick and placehead 512, using control arm supports 508 and 510.

[0047] After components 504 are placed on the embossed layer of tape102, the sealing layer of tape 102 is sealed over the embossed layerusing a suitable sealing mechanism, such as vacuum, heat, or pressure,so that the components are immobilized within tape 102. Tape 102 is thentransferred to stretching and inversion mechanism 106, where it isilluminated by light source and polarizer system 300 as shown in FIG. 3.If a defective component is detected by inspection system 522, thenfeeder reel 104 and take-up reel 118, and other suitable feedingmechanisms are reversed, such that 102 is taken up on feeder reel 104and fed by take-up reel 118. In this mode of operation, tape 102 isdetaped by tape/detape mechanism 520, and components 504 are removedfrom tape 102 until all defective components have been removed. Thefeeder reel 104 and take-up reel 118 may then be reversed to theiroriginal direction, such that components may be taped an inspected asrequired.

[0048]FIG. 6 is a flowchart of a method 600 for inspecting componentsafter they have been sealed in a packing material, in accordance with anexemplary embodiment of the present invention. Method 600 may be used toinspect components that have been sealed beneath a tape layer todetermine whether such components have been damaged or improperlyselected for sealing.

[0049] Method 600 begins at 602, where components are packed and sealedwithin an embossed carrier tape layer and sealing tape layer. Thecomponents may be placed in an embossed compartment of a carrier tapewhile a cover or sealing tape is placed on top of the carrier tape,after which the two tape layers are sealed together using a suitablemechanism, such as a vacuum, heat, or pressure, such that the componentis disposed between the embossed carrier tape and the sealing tapelayer. The method then proceeds to 604, where the sealed tape containingthe components is transferred to the inspection system, such as bydirectly feeding the sealed tape into the inspection system, by loadingthe sealed tape onto a reel, or by other suitable methods. The methodthen proceeds to 606.

[0050] At 606, the tape enters a stretching and inversion mechanism, inwhich the sealing tape layer is stretched in a manner that removes anysurface unevenness. The method then proceeds to 608, where the tapelayer is inverted to both minimize the distance between the componentsand the sealing tape layer, and to ensure that the components are in auniform location relative to the sealing tape. Light is then emittedfrom a light source at 610, and passes through a polarizer at 612 so asto allow the component to be illuminated with planar polarized light.The method then proceeds to 614.

[0051] At 614, the planar polarized light passes through the sealingtape layer, where it falls incident upon the component. At 616, light isreflected and emitted from the tape and the component disposed beneaththe tape. This light passes back through the first polarizer at 618,which may include an aperture that allows the light to pass throughwithout polarization at this stage. The image light then passes throughthe second polarizer at 620, which may be adjustable so as to removescattered polarized light from the tape sealing layer covering thecomponent, and is received by the camera at 622. The method thenproceeds to 624, where image data is generated by the camera. The imagedata is then transferred to a data storage device, such as a randomaccess memory, a magnetic memory, or other suitable data storage device.

[0052] After the image is stored as pixels in a data storage device, themethod proceeds to 628 where it is determined whether the image datawill be used to create template data. If template data will be created,then the method proceeds to 630 where a user is prompted to selectboundaries for the leads, markings, seals, component dimensions withinthe packaging, and other suitable template data. In one exemplaryembodiment, a graphical user interface is provided that allows the userto select coordinates of the template image and to specify boundarylines that should pass through the selected coordinates. For example,the user may select one point in the template image, and may thenspecify that a circular boundary should pass through this point. Theuser may then alter the size and location of the circle by “clicking anddragging” the circle. The method then proceeds to 632, where theuser-entered data is used to generate a template for the inspection ofcomponents. The method then returns to step 622.

[0053] If it is determined at step 628 that template data is notrequired, the method proceeds to step 636. At step 636, the pictureelement data values are used to determine whether any features of theinspected component exceed allowable tolerances defined in the template.The method then proceeds to step 638 where it is determined whether toaccept or reject the component. In one exemplary embodiment, a componentwill be accepted or rejected based upon whether the picture element datafor that component correlates with picture element data for thetemplate. For example, the user-selected template data may define anallowable range for features of the component being inspected. The rangeselected for the leads, edges, and markings of the device may define anallowable area within which picture elements for any given lead, edge,or marking may be found. Likewise, the template image or a compositetemplate image may be used to compare with the tested component on apixel-by-pixel basis. If the number of pixels in which a difference inpixel data is observed exceeds a predetermined allowable number ofpixels, then the component may be rejected. Likewise, if the absolutemagnitude difference in the pixel data exceeds a predetermined allowabledifference for a predetermined number of pixels, then the component maybe rejected. Furthermore, rather than automatically rejecting thecomponent, the method may include notifying an operator of a suspectcomponent. The operator may then review the image data and decidewhether to investigate further.

[0054] If it is determined at 638 that the component should not beaccepted, then the method proceeds to 640. At 640, the componentlocation is marked by a suitable method, such as by recording an indexvalue, by physically marking the tape, or by other suitable methods. Thecomponent may also or alternatively be removed at step 640, such as by ataping-detaping mechanism. The method then returns to step 622 whereimage data for the next component is obtained.

[0055] In operation, components are inspected after they are sealed intape. The tape is first inverted, such that the components are forced tolie flat on the sealing tape layer by action of gravity. The sealingtape layer is also stretched, to ensure that the surface of the sealingtape layer is flat and creates minimal distortion. Light from a knownlight source is then used to illuminate the component. The light ispolarized to help eliminate distortions that may be caused byreflections or other similar lighting anomalies.

[0056] Although preferred and exemplary embodiments of a system forinspecting components that have been sealed in a packing material havebeen described in detail herein, those skilled in the art will alsorecognize that various substitutions and modifications may be made tothe systems and methods without departing from the scope and spirit ofthe appended claims.

What is claimed is:
 1. A system for inspecting components that aresealed within tape comprising: a light source configured to illuminatethe components through a tape layer; a polarizer configured to polarizelight from the light source, the components, and the tape layer; and animage system configured to receive light from the polarizer, the imagesystem operable to store image data of each component.
 2. The system ofclaim 1 wherein the light source further comprises an array of lightemitting diodes arranged in a circular pattern at a predetermined angle.3. The system of claim 1 wherein the polarizer further comprises a firstpolarizer and a second polarizer, and the light source is arrangedbetween the first polarizer and the second polarizer.
 4. The system ofclaim 1 wherein the image system further comprises a digital camerahaving an array of picture elements, each picture element operable togenerate a numerical value corresponding to the intensity of apredetermined frequency band of electromagnetic radiation that isreceived by the picture element.
 5. The system of claim 1 furthercomprising an inspection system coupled to the image system, wherein theinspection system is operable to process picture element data todetermine whether the picture element data is within a predeterminedallowable range.
 6. The system of claim 5 further comprising a markingsystem coupled to the inspection system, the marking system operable totrack the location of a component when the inspection system determinesthat the picture element data for that component is not within thepredetermined allowable range.
 7. The system of claim 1 furthercomprising a tape stretching and inversion system configured to invertthe tape containing the components and to stretch the tape, such thatthe components that are sealed within the tape are made to lay flatagainst a sealing tape layer, and such that the sealing tape layer isstretched flat.
 8. The system of claim 5 further comprising ataping/detaping system coupled to the inspection system, thetaping/detaping system operable to remove components from the tape whenthe inspection system determines that the picture element data for thatcomponent is not within the predetermined allowable range.
 9. A systemfor inspecting components sealed between a top tape layer and a bottomtape layer comprising: a tape stretching system operable to stretch thetop tape layer; an inversion system coupled to the tape stretchingsystem, the inversion system configured to invert the tape layers suchthat the top layer is disposed on the bottom and the bottom layer isdisposed on the top; and an image processing system configured tocapture and store image data of the components through the inverted toptape layer.
 10. The system of claim 9 wherein the tape stretching systemcomprises a semi-circular track.
 11. The system of claim 9 wherein theinversion system comprises a semi-circular track.
 12. The system ofclaim 9 wherein the tape stretching system and the inversion systemcomprise a semi-circular track that is configured to stretch the tapewhile simultaneously inverting the tape.
 13. A method for inspectingcomponents that are sealed between a top tape layer and a bottom tapelayer comprising: stretching the top tape layer; inverting the tapelayers such that the top tape layer is disposed on the bottom and thebottom tape layer is disposed on the top; capturing an image of eachcomponent through the top tape layer; and generating image data of eachcomponent.
 14. The method of claim 13 wherein stretching the top tapelayer comprises feeding the tape layers through a semi-circular track.15. The method of claim 13 wherein inverting the tape layers comprisesrotating the tape layers through a semi-circular track.
 16. The methodof claim 13 wherein capturing an image of each component comprisesgenerating data from a plurality of picture elements.
 17. The method ofclaim 13 further comprising processing the image data to determinewhether the image data is within a predetermined acceptable range. 18.The method of claim 17 wherein processing the image data to determinewhether the image data is within the predetermined acceptable rangecomprises: displaying a template image; receiving user-entered data thatdefines allowable ranges for features of the template image; andgenerating template data from the template image and the user-entereddata.
 19. The method of claim 18 wherein receiving user-entered datathat defines allowable ranges for features of the template imagecomprises creating a graphical user interface that allows the user toselect coordinates of the template image and to specify boundary linesthat should pass through the selected coordinates.
 20. The method ofclaim 13 further comprising comparing the image data to template data todetermine whether the image data is within a predetermined acceptablerange.